Automatic molding apparatus



May 8 1945; k I G. B. SAYRE v 7 AUTOMATIC MOLDING APPARATUS Filed Dec. 2, 1939 17 Sheets-Sheet 1 INVENTOR GORDON B. SAYRE g M $72M,

ATTORNEY May 8, 1945.

Filed Dec.- 2, 19:59 17 Sheets-Sheet 2 VINVEN'I'OR v .cmzxwa am?! y May 8, 1945. ca. B. SAYRE AUTOMATIC MOLDING APP RATUS Filed Dec. 2, 1939 17 Sheets-Sheet 3 "an" annual ATTORNEY y 8, 1945. e. B. SAYRE AUTOMATIC MOLDING APPARATUS 17 Sheets-Sheet 4 Filed Dec. 2, 1939 INVENTOR R 7 wwm a w May 8, 1945. G. B. SAYRE AUTOMATIC MOLDING APPARATUS 17 Sheets-Sheet 5 Filed Dec. 2, 1939 I INVENTOR 64 900 8- \SY/Pf ATTORN EY May 8, 1945.

5. B. SAYRE AUTOMATIC MOLDING APPARATUS Filed Dec. 2, 1939 17 Sheets-Sheet 6 INVENTOR 00/900 8. Jam:

BY k9 ATTORNEY W ,M W Q 9 5 I v 7. .5 7 D a l. 3 F Dw 2 B 5 w 53; 2 n z. 3 z a n. M

y 1945- G. B. 'sAYRE AUTOMATIC MOLDING APPARATUS 17 Sheets-Sheet 7 Filed Dec. 2, 1939 INVENTOR GORDOIYB. $705 BY M ATTORNEY May 8, 1945.

G. B. SAYRE 2,375,252

AUTOMATIC MOLDING APPARATUS Filed Dec. 2, 1939 17 Sheets-Sheet? I /HS 1 i l ,4l5 l v 'INVENTOR/ o m B. SAX-R/E .2 ni i wlir l. l tram l7 Sheets-Sheet 9 G. B. sAYRE AUTOMATIC MOLDING APPARATUS Filed Dec. 2, was

I46 INVENTOR GORDON BSAYRE gf 'mX 5 ATTORNEY May a, 19 45,

May 8, 1945.

G. B. SAYRE AUTOMATIC MOLDING APPARATUS Filed Dec. 2, 1939 17 Sheets-Sheet 11 High INVENTOR GORDON B. SAYRE fill/N7 a ATTORNEY May 8, 1945.

G. B. SAYRE AUTOMATIC MOLDING APPARATUS Filed Dec. 2, 1939 1'7 Sheets-Sheatl2v INVENTOR GORDON B. SAYRE ATTORNEY M8418? 1945@ a YRE 2 375252 AUTONA'IIC MOLDING krmRArus Filed Dec. 2. 1939 1:1 Shseis sheet 13 Low H igh Release INVEWifiR GORDON a spam May 8, 1945. G] B; SAYRE 2,275,252

AUTOMATIC MOLDING APPARATUS Filsd nemz, 1929 lTSheets-Sheet 14 mwzmmm 1 GQRDON s. .SAYFZE ATTORNEY FHi FFess Vain/a y 8, 1945. G. B. SAYRE ,252

AUTOMATIC MQLDING APPARATUS Filed Dec. 2, 1939 17 Sheei s-Sheet-IS GQRDON B.--SAYRE 2-75. 55 {BY K 624 ATTORNEY y 8, 1945. G. B. SAYRE 2,375,252

AUTOMATIC MOLDING AFPARATUS Filed Dec. 2; 1939 17' Sheets-Sheet 16 L Rail Swifch INVENTOR GORDON B. SAYRE F242 52 1 K I ATTORNEY May 8, 1945. G. B. SAYRE AUTOMATIC MOLDING APPARATUS Filed Dec. 2, 1939 17 Sheets-Sheet 17 4 0 a Q Q w G M? V f y 5/545 F7544 m INVENTOR GORDON B.' SAYRE ATTORNEY Patented May 8, 1945 UNITED STATES PATENT OFFICE AUTOMATIC MOLDING APPARATUS Gordon B. Sayre, Boonton, N. J., assignor to Boonton Molding Company, Boonton, N. .I., a corporation of New Jersey Application December 2, 1939, Serial No. 307,263

77 Claims.

This invention relates to molding, particularly the molding of plastics.

The primary object of my invention is to generally improve the molding of plastics. A more particular object is to provide molding appaabout the formation of preforms or so-called pills during the transformation of the molding powder into the finished product. A plurality of pills may be made simultaneously, and the relative mass or weight of the pills may be independratus so fully automatic that it may be supplied 6 ently adjusted for subsequent delivery to dewith a container or barrel of molding powder at sired parts of a single large mold cavity, or to one end, and will deliver finished molded pieces the cavities of a multiple cavity mold. This at the other end, all without manual intervenfeature is broadly disclosed and claimed in my tion of any kind. 10 co-pending application, Serial No. 247,017, filed An important object of the present invention December 21, 1938, and entitled Molding. This is to provide such an apparatus which does not is of great value even with supposedly uniform discard, but instead retains those elements and mold cavities, for in practice they are not exprinciples which have survived as most satisactly uniform, and if the pills a e d mens n d factory in the course of decades of work with for the largest cavity then there is excessive molding presses, molds, stripping mechanisms, flash and waste at all of the other cavities. In and control valves. The press and mold designs the present apparatus, each pill cavity is defiare not radically altered, and their usual denitely related to a compan o or melting mold pendability and versatility are retained. Screw cavity, and the amount of poWder del ver d t stem valves are retained for the main purpose each pill cavity is independently adjustable o because of their many advantages, but these prov de e actly the co c mo n of molding are arranged for automatic control, in much material. This reduces the task of finishing the the manner disclosed in by co-pending applicaproduct for removal of the flash or fin. tion, Serial No. 239,933 filed November 12, 1938, The pi l Dress S heated n o e o p t the and its divisional application Serial No. 427,594, pi s durin ma u a tu at n s a critifiled January 21, 1942, entitled Automatic valve cal matter, for if the pill is cured far enough to control for hydraulic press. In accordance with st fen before ea h the m l p s, it Will my invention. I provide actual clock timing for. t o d p p y, d m y e damage the both the low and high pressure treatment in the mold. Inasmuch as the present apparatus is press, and these times are readily independently n r ly automatic and operates in accordance adjustable at the clocks, the adjustment being With a definite time Cyc e, th r s no danger made in actual time units (minutes and sect eh d t p e t of t e pills, and this p eonds). This is to be contrasted with convenheating may be carried much further than tional cam shaft timing, in which the changes u d t e w se be po s ble. As aresult the are not readily made, and when made, are not molding or curing time in the main p ess is independent of one units.

The invention in the particular example here illustrated is shown applied to a press carrying a large mold for a considerable number of small parts. In a general way the method in such case includes periodically simultaneously measuring out independently predetermined amounts of molding powder for each mold cavity, periodically transferring the measured amounts of powder simultaneously to an array of pill molds, and periodically compressing and heating the measured amounts of molding powder simultaneously to form a plurality of heated pills, one for each mold cavity. The array of pills is then bodily transferred to the molding press, each pill to its corresponding mold cavity. and there the pills are all simultaneously subjected to heat and pressure for a predetermined time.

Still another object of the invention centers another, nor in actual time greatly shortened, and this speeds up the entire operating cycle of the machine. Moreover, the finished product is of better quality, and pieces which have delicate inserts or which are too complex to be made with cold pills are readily made in the present machine. During passage from th pill press to the molding press the heated pills are relieved of pressure, and gas generated therein is freely vented, thus dispensing with the need for bumping or venting at the main press.

It has already been mentioned that the actual timing of the cure in the molding press is by means of clocks. However, the timing of the complete apparatus is by means of a cycle control shaft. One object of the present invention is to reconcile these apparently conflicting controls, and in accordance with my invention, the cycle control shaft is operated in step by step fashion, and at an appropriate step initiates the closing of the main press. When the press has closed the clocks take over control until the de sired low and high pressure curing times have elapsed, whereupon the step by step operation of the cycle control shaft is resumed and the apparatus is again under control of the latter.

At a number of points in the operation of the apparatus the movement of a valve functions to initiate the movement of another valve or the starting of a clock or movement of the cycle control shaft. In accordance with a feature and object of the present invention the transmission of a control impulse for this purpose is in response to completion of the valve movement, and not merely starting of the valve movement. This applies to the pill press valve as well as the main press valve.

A further object of the invention is to compare the time for the complete molding cycle with a predetermined normal or maximum safe time, and for this purpose, I provide a safety-stop clock which is automatically reset at the end of each normal molding cycle, but which operates to shut down the entire apparatus if its predetermined allowed time runs out before the molding cycle is completed.

The pills are transferred from the pill press to the molding press by means of a pillboard, while the finished product stripped from the molding press falls onto a catchboard. These are preferably connected together for simultaneous movement along guides running through the presses. A further object is to minimize the necessary space between the presses, and to economize in time, and in accordance with the present invention the power unit which moves the pillboard and catchboard (which together may be called the loader), so times the movement of the loader that the pillboard is kept in the pill press during the pill molding operation, the pill press working through the pillboard.

Further objects of the invention center about the power unit for moving the loader. It is desired that this not only move the loader with a step by step movement, but also look it in position after each step of movement. For this purpose the movement is taken through single revolution clutches having automatic locking means. The arrangement preferably includes sprocket wheels which drive chains for moving the loader, said sprocket wheels having a periphery equal to one step of movement of the loader. The sprocket shaft carries differential pinions meshing with forward and backward running differential gears freely rotatable on the sprocket shaft. The driving motor is geared to a countershaft carrying two single revolution clutches, one of which is geared to the forward running differential gear, and the other of which is reversely geared to the backward running differential gear. With this arrangement one differential gear may be run while the other remains locked, and both are locked between movements of the loader.

I have found that forcible molding of the pills against the ejection plugs creates a vacuum between the pill and the plug, causing the pill to adhere strongly to the plug. An object of the. present invention is to overcome this difiiculty and to provide means for dislodging the pills from the plugs. For this purpose, the lower lamination of the pillboard is made the movable lamination, and a relatively powerful motor driven means is provided to close the pillboard by moving the lower lamination. This movement then functions to dislodge the pills and to at the same time grip the same in the pillboard.

Further objects of the invention are to interlock various steps or operations of the apparatus to prevent conflict or improper sequence. One such object is to prevent the molding press from going ahead with its clock timed cycle until the pill press has finished its preceding cycle. Another object is to eliminate this requirement in the event that the pill press is not started at all, for in such case the molding cycle may continue to complete the molding of the last set of pills when the apparatus is being shut down.

Another object is to prevent the ejection of pills unless they have been adequately pressed to desired small dimension. Another object is to prevent the ejection of pills, unless the pill press has first opened. Still another object is to prevent movement of the pillboard away from the pill press until after the press has opened, and also until after the ejection plugs have been raised and again lowered out of the way of the pillboard. A further object is to prevent the ejection plugs from lowering until after the pillboard has been closed in order to dislodge the pills from the ends of the ejection plugs and to grip the pills.

Another object is to provide appropriate safety means to shut down the apparatus if the stripper mechanism at the main press fails to strip the molded pieces from the mold. This shut down is immediate with the catchboard still in the molding press.

Still another object is to shut down the apparatus if the heating means for the mold fails so that the mold gets cold, and in this case the apparatus is shut down between complete moldin cycles.

Another object of the invention is to shut down the apparatus in the event that the pillboard is not retracted fully into proper position in the pill press, for otherwise the pill press might smash the pillboard and the main press might smash the catchboard.

Another object is to insure not only retraction of the pillboard, but also that the pillboard is in open condition before the pill press cycle pro ceeds.

Further objects of the invention center about the powder measuring apparatus. This is in the main disclosed in my co-pending application, Serial No. 272,769, filed May 10, 1939, and entitled Apparatus for measuring, preforming and molding plastics. In accordance with a feature and object of the present invention, the powder measurer is provided with weight control means for automatically starting and stopping a conveyor delivering powder to the hopper of the powder measurer, in order to keep the powder in the hopper between desired limits.

A further object is to prevent discrimination in the amount of fine and coarse particles of molding powder reaching the measuring cups, and to this end I provide a mixing means or stirrer in the powder hopper.

Still another object is to obtain accurate measurement by insuring complete filling and complete emptying of the measuring cups, and for this purpose the measuring cups are provided with a vibrator, preferably consisting of a motor with eccentric weights thereon. The vibrator is preferably operated only during the measuring and delivery of molding powder, and I provide switch means for this purpose.

Still another object is to make the design of the apparatus adaptable to different sizes of press. The space between the guide rails is selected to fit the size of the molding press. The space between the molding press and the pill press is selected to equal the size of the catchboard and pillboard, so that the loader may be moved in equal steps through its three positions. No change is needed in the power unit, for the spacing between the sprocket wheels on the sprocket wheel shaft may be accommodated to the spacing between the guide rails, and the diameter on the sprocket wheels may be accommodated to the size of the step by step movement of the loader.

To the accomplishment of the foregoing and other objects which will hereinafter appear, my invention consists in the molding apparatus elements and their relation one to the other as hereinafter are more particularly described in the specification and sought to be defined in the claims. The specification is accompanied by drawings, in which:

Fig. 1 is a side elevation of a complete molding apparatus embodying features of my invention;

Fig. 2 (on the same sheet as Figs. 16-18) is a schematic view showing the pill press and molding press in closed condition;

Fig, 3 schematically illustrates the apparatus after the molding operation, with the pill press open and the molding press half open;

Fig. 4 schematically illustrates a later stage in the operation, with the catchboard moved into the molding press, and the latter fully opened to strip the molded pieces onto the catchboard;

Fig. 5 shows a still later stage, during discharge of the finished pieces and renewed loading of the presses for another molding cycle;

Fig. 6 is a side elevation of the powder measurer;

Fig. 7 is a partially sectioned plan view of the powder measurer;

Fig. 8 is an elevation of a detail looking in the plane of the line 8-8 of Fig. 7;

Fig. 9 is a section through one of the measuring cups during the powder measuring operation;

Fig. 10 is a similar section showing discharge of the measured powder;

Fig. 11 is a section at a pill cavity in the pill press, showing loading of the same with powder;

Fig. 12 is a fragmentary section at the pill press showing the pill pressing operation;

Fig. 13 is a plan view of the mechanism for advancing and retracting the powder carrier;

Fig. 14 is a side elevation of the limit switches associated with said mechanism;

Fig. 15 is a detail of the cams for operating the limit switches;

Fig. 16 is an end elevation of the mechanism for moving the powder carrier;

Fig. 17 is a section taken in the plane of the line |'|--l'| of Fig. 13;

Fig. 18 is a side elevation of a rail switch associated with the powder measurer;

Fig. 19 is a partially sectioned elevation of the pill press, taken transversely of the guide rails;

Fig. 20 (same sheet as Figs. 3-5) is a fragmentary plan View of the pillboard, showing the same in open condition at the molding press:

Fig. 21 is a fragmentary plan view showing the pillboard in closed condition at the pill press;

Fig. 22 is a partially sectioned elevation through the pillboard closing linkage of the pillboard;

Fig. 23 is an elevation of the power unit which controls the entire apparatus and which moves the loader;

Fig. 24 shows the opposite side of the power unit, carrying the sprocket shaft which moves the loader;

Fig. 25 is a plan view of a sequence relay associated with the powder measurer;

Fig. 26 is a side elevation thereof;

Fig. 27 is a transverse section looking in the direction of the arrows 21, 21 of Fig. 26;

Figs. 28 through 40 together constitute a complete wiring diagram for the apparatus;

Fig. 28 shows the wiring associated with the timing clocks and control switches;

Fig. 29 shows the wiring associated with the cycle control mechanism;

Fig. 30 illustrates the wiring associated with the valves for the main molding press;

Fig. 31 shows the wiring associated with the pill press;

Fig. 32 shows the wiring associated with the powder measurer;

Figs. 33 through show additional wiring de tails, and are further explanatory of the operation of the apparatus;

Figs. 41 and 42 are explanatory of certain forward and backward running gears used in the power unit for moving the loader;

Figs. 43 and 44 are explanatory of the clutch tripping cams mounted on the cycle shaft or main cam shaft in the power unit;

Fig. 45 is a fragmentary side elevation explanatory of the attachment of the chain to the pillboard;

Fig. 46 is a section taken in elevation through a self-locking single-revolution clutch forming a part of the power unit;

Fig. 47 is a transverse section taken in the plane of the line 41-41 of Fig. 46;

Fig. 48 is a bottom view of the driven part of the clutch, with the other parts omitted;

Figs. 49 and 50 are explanatory of the operation of the vanes of the powder carrier; and

Fig. 51 is a schematic illustration of a valve used on the pill press.

Referring to the drawings, and more particularly to Fig. 1, the complete molding machine is so designed as to take a conventional barrel or container of molding powder. indicated at 4|,

and to transform the same into finished molded pieces which are descharged at the opposite end of the machine. The machine comprises a powder measurer generally designated 43, a pill press generally designated 45, and a main press or molding press generally designated 41. Powder is transferred from container 4| to the hopper l0| of the powder measurer by means of a conveyor H2. The powder in hopper HIM is mixed by a stirrer driven by motor 034. The measured powder is transferred from the measurer 43 to the pill press 45, by means of a powder carrier which is not visible in this figure of the drawings, but which is described later. The pills are transferred from pill press 45 to molding press 41 by means of a pillboard 49, movable along rails 69. The finished pieces, when stripped from the molding press. are deposited on a catchboard 5|.

The general plan of operation may be briefly outlined with reference to the schematic showing in Figs. 3 through 5 of the drawings. and also Fig. 2 (which is grouped with Figs. 16 thr ugh 18). In Fig. 2. both presses are closed, this showing the condition of the machine durin the molding operation. The pillboard 49 is in the pill press, while the catchboard 5| is between the presses. The molding press 4'! closes by raising its lower platen 53, this being done by a main ram 55. The pill press is closed by lowering of its upper platen 51, which carries the force plugs 59 for compressing the pills. The 

